In the world’s premier beverage trade show, which will be held in Munich from September 15–19, 2025, Netstal is presenting a particularly eye-catching injection molding exhibit with a PET-Line 4000 of the most recent generation.
At its booth, the Swiss mechanical engineering company will be producing 6.9 gram preforms with a 25/22 thread. PET resin with a share of 30% rPET is processed. In the interests of sustainability, the preforms produced are then fed back into the PET recycling loop.
Ready for high cavity molds
Part of the innovative injection molding solution is a newly developed mold from Krones Group sister company MHT with 144 cavities and an integrated self-cleaning function. The PET-Line 4000 operates the mold with an extremely fast cycle time of 4.8 seconds. With around 108,000 preforms per hour, it is one of the most productive systems with a clamping force of 400 tons. For higher output with the same clamping force, MHT also offers a suitable mold with 160 cavities. If a maximum output is required, customers opt for the larger PET-Line 5000, which can be equipped with up to 192 cavities.
Leading the way in energy efficiency
A key element in increasing overall efficiency in the production of preforms is the continuous optimization of energy efficiency. With the integrated recuperation of kinetic braking energy from the clamping unit and post-mold cooling station, Netstal’s PET-Line is already the most energy-efficient system on the market. Thanks to the optional System Pressure Reduction, the PET-Line is now even more efficient. When this function is activated, the pressure in the hydraulic system is continuously maintained at the optimum point, which is often below the maximum pressure. This also reduces energy consumption in the overall system and lowers the ecological footprint of production. Compared to similar systems from the competition, a PET-Line from Netstal can save annual energy costs in the five-digit euro range.
Integrated quality monitoring and quality shot
The highest output is useless if the quality of the preforms produced is not kept constant. Netstal has therefore always attached immense importance to high precision, repeat accuracy and long-term stability in the injection molding process. For decades, Netstal machines have impressed users with the highest proportion of good parts. Nevertheless, quality must be checked and documented in real time in a modern system. In cooperation with its partner IMDvista, Netstal has integrated a modern quality monitoring system into the PET-Line. The camera-based inspection system guarantees real-time detection of any defects that may occur. The inline inspection can also be used very flexibly for new preform designs and has an intelligent self-learning function for all cameras and inspection steps. With integrated quality control, users can identify potential weak points in the injection molding process at an early stage and make optimizations. In addition, the quality of the delivered batches can be fully documented for the customer.
Furthermore, the new and fully integrated Quality Shot offers the option of taking random samples and subjecting the preforms to in-depth laboratory testing on request. For this purpose, the system transfers the preforms of a complete shot to an additional conveyor belt and places them in a separate box.
Tasks make operation even more intuitive and secure
Netstal supports preform manufacturers in continuously maximizing their production efficiency. This is why the Swiss company also focuses on flexible and intuitive operability so that users can get the most out of their system. The integrated 4-button Smart Operation control supports the operating personnel with clear instructions and color-coding during production start-up. Waiting times are minimized and operating errors are reliably eliminated. With the new tasks, Netstal is now going one step further and offers smart support for more complex challenges in day-to-day production. Tasks are step-by-step instructions integrated into the Axos machine control system. The first of these is the Quick Mold Change task, which provides operators with an assistant for quick and efficient mold changes. With clear graphics and descriptions of the individual work steps, mold changes can be conducted by less experienced personnel in the shortest possible time. The new Quick Mold Change task offers a challenge frequently mentioned by customers. Further tasks will follow in the coming months and years.
Digital partner bfa solutions will present the integration of the entire production system into its MES solution. The connection is made via the existing standard interfaces based on OPC-UA and Euromap for injection molding machines and peripheral devices.
Trade fair exhibit with established system partners
In addition to the companies already mentioned, the following system partners participate in the drinktec trade fair exhibit. Neopet is supplying the Food Grade PET Cycle 80-R30. The material conveyor, material dryer and mold dehumidifier are supplied by Eisbär. EF Cooling supplies the chiller.
